Spring locating apparatus for box spring assemblies

ABSTRACT

A corner assembly for a box spring frame which forms a reinforced corner and which supports and locates a corner spring element. The corner assembly can be in the form of an individual bracket which also connects wooden frame rails.

United States Patent [191 nu 3,824,639

Mandusky [45] July 23, 1974 [54] SPRING LGCATING APPARATUS FOR BOX SPRING ASSEMBLES [56] References Cited [75] Inventor: Jack C. Mandusky, Lexington, Ky. UNTTED STATES PATENTS [73] Assignee: Hoover Ball and Bearing Company, 1,694,359 12/1928 Trimble 5/26() Saliney Mich 2,039,125 4/1936 swan 40s/403 x 2,657,439 ll/l953 Levine 5/351 X [22] Filed: May 17, 1973 [2l] Appl. No.: 361,137 Primary Examiner-James C. Mitchell Related US. Application Data Attorney, Agent, or Firm-Olsen and Stephenson [63] Continuation-impart of Ser. No. 264,818, June 2l,

1972, abandoned. [57] ABSTRACT A comer assembly for a box spring frame which forms [52] U-S- CL 5/260, 5/264 B, 403/205, va reinforced corner and which supports and locates a 403/403 corner spring element. The corner assembly can be in Int. vthe form of an individual bracket also connects 0f Search Wooden frame rails.

5/259 R, 259 B, 260, 263, 264 B, 264 R, 282 R,288, 304, 351; 403/205, 403

10 Claims, 8 Drawing Figures 1 SPRING LOCATING APPARATUS FOR BOX SPRING ASSEMBLIES CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of U.S. Pat. application Ser. No. 264,818 filed June 21, 1972, and now abandoned.

BACKGROUND OF THE INVENTION In constructing box spring assemblies a rectangular wooden frame is constructed to support the spring elements. The springs mounted along the edge of the wooden frame are joined together to form a border wire so that the springs are laterally constrained with respect to each other in their reaction to loading along the edge of the box spring assembly.

In the past, the wooden frames were joined at the corners by wooden gussets. The quality and strength of the joint depended on the quality of wood Aused for the gusset and the skill of installation. In order to restrict the lateral movement of the border wire and the connected springs, the border wire had to be anchored to the wooden frame by stapling each edge spring to the wood frame'. This method was time consuming and failed to provide the proper lateral constraint.

SUMMARY OF THE INVENTION The present invention provides a metal cornerV bracket which overcomes both the problem of corner reinforcement for the wooden frame and the problem of lateral location for the border wire spring element. The bracket consists of two channeled sections set at right angles to each other. An integral metal gusset is provided at the vertex of the angle for strength. The wooden frame rails are seated within the channel and secured by integral tabs which have been stamped out of the bracket and have a portion bent perpendicular to the frame rails. The tab is then driven into the wooden rails to fasten the bracket to the rails and thus provide a reinforced corner joint. The bracket also has upstanding tabs on its upper surface which engage a spring element that forms the border wire.

Thus one object of the present invention is to provide a metalbracket for forming reinforced corner joints in a box spring assembly. A further object is to provide a corner bracket which will support and locate a spring element on a box spring assembly. Still a further object is to provide corner brackets which are connected to a frame rail so as to provide a bracket and frame rail assembly that can be used for frame reinforcement and spring locating purposes. y

VFurther objects, features and advantages of this invention will become apparent from a consideration of the following description, the appended claims, and the accompanying drawing in which:

FIG. 11 is a top plan view of a box spring frame with the brackets mounted at each corner vand the border wire spring elements mounted on the brackets;

FIG. 2 is an enlarged fragmentary perspective view of one corner of the assembly shownin FIG. l;

FIG. 3 is a sectional view of the bracket as seen along line 3-3 of FIG. 2;

FIG. 4 is a sectional view of the bracket as seen along line 4-4 of FIG. 2;

FIG. 5 is a plan view of a modified form of this invention wherein a pair of corner brackets are formed integral with a connecting frame rail;

FIG. 6 is a foreshortened plan view of another modified form of this invention in which a pair of bracket assemblies are releasably 'connected to a frame rail extending therebetween;

FIG. 7 isan enlarged fragmentary sectional view of a rail and bracket connection as seen from the line 7-7 in FIG. 6; and

FIG. 8 is a fragmentary perspective view of a box spring frame provided with the bracket and frame rail assembly shown in FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENT ments such as coil springs, formed wire springs and the like. In the illustrated embodiment of the invention, the

velements 20 are connected by clips`22 to form a rectangular border wire 23 supported at its corners and disposed above the frame l0.

Each bracket 17 (FIG. 2) consists of a flat top portion 24 divided into two end segments 26 and 28 which are disposed at right angles to each other and have a gusset segment 30 formed therebetween. Right angle web portions 32 and 34 are provided for engaging the inner edges of the rails 12 and 14 to locate the top portion 24.

Triangular fasteners 36 are stamped out of end segments 26 and 28 (FIGS. 2 and 4). Each fastener 36 is initially bent upwardly along a line 37 from the end segment, as shown in phantom lines in FIG. 4. Each fastener 36 is also bent at right angles upon itself so that it has two portions 38 and 40. The fastener 36 is configured so that portion 40 is located essentially perpendicular to the frame rail 14 located therebelow. To connect the bracket 17 to the wooden rail, the fastener portion 40 is driven into the wood by striking the fastener 36.

The top portion 24 of the bracket 17 is also formed with a plurality of slots 50, arranged in pairs so that sta ples can be driven through pairs of slots 50 to secure the bracket 17 to the rails 12 and 14. In the illustrated embodiment of the invention shown in FIG. 2, two staples 52 are shown extending through two pairs of slots 50. The staples 52 can be used instead of the tabs 36 or in addition to the tabs 36, as desired, in mounting the brackets 17 on the rails 12 and 14. An embossment 53 is provided between each pair of `slots 50 for stiffening purposes and to facilitate location of a stapling gun to drive a staple through the slots.

The bracket 17 also has two inwardly facing upright tabs 42 and 44 and an outwardly facing tab 46 struck from the flat portion 24 of the bracket 17. The tabs 42, 44 and 46 are concave so that they can seat the curved sinuous end portion 2l of the spring element 20. The end portion 48 is in a stressed condition when it is engaging the insides of the tabs 42 and 44 and the outside of the tab 46 and is thus held in place. A different tab arrangement is employed if a different type of spring, such as a coil spring, isused.

Each spring element 20, besides being sinuous in a vertical direction, is curved to conform to the corner I6 formed by the bracket 17. This curvature gives the spring element 20 lateral stability along both rails l2 and 14. The border wire 23 is formed by clipping the spring elements 20 as shown in FIG. l.

Thus the brackets 17 provide reinforcement for the wooden frame and a laterally stable mounting for spring elements which support the border wire 23 for a box spring assembly.

A modified form of the invention is illustrated in FIG.

`5 in the form of a corner bracket and end rail assembly 60. The assembly 60 has end brackets 62 which are identical to the corner brackets 17 described abovel and are, therefore, not described in detail. The corner brackets 62 are connected by an integral end rail 64 having upstruck tabs 66 formed therein for mounting spring elements thereon. Thus, the assembly 60 is an extension of the corner bracket concept described above to form two corner brackets 62 with an integral connecting end rail 64. The end rail 64 has an inner flange 68 which is vertically disposed to accommodate a wooden end rail orstrip on the underside of the rail 64. The wooden strip is necessary to provide a tacking surface for the cover for the box spring.

In FIG. 6 still another modified form of the invention is illustrated. A corner bracket and end rail assembly 70 is illustrated in FIG. 6 as consisting of a pair of corner bracket assemblies 72 that are identical to the corner brackets 17 previously described and an end rail 74 which extends between and is removably connected to the assemblies 72. As shown in FIG. 6, the ends of the end rail 74 are formed with upwardly extending and bent over tabs 76 which project through offset slots 78 in the end assemblies 72 (FIG. 7). As a result, the assembly 70 can be assembled with an end rail 80 and a side rail 82 at the frame corner 84 so as to reinforce the corner and provide for support and location of the spring element 20. Upstruck tabs 86 on the end rail 74 function to support some springs 88 in the box spring assembly. Other springs 90 in the assembly are mounted on cross rails, such as the one indicated at 92 supported on the side rail 82.

From the above description it is seen that this invention provides a corner bracket 17 which functions to both reinforce the box spring frame and support and locate a spring 20. As shown in FIGS. 5 and 6, the corner bracket concept can be expanded into pairs of corner brackets which are integral with a metal frame rail that is in turn assembled with conventional wooden strips as shown in FIG. 8.

What is claimed is:

l. In a box spring assemblyhaving a rectangular frame with side and end rails joined to form corners and a border wire disposed above the frame, corner bracket means comprising a body member having flat end segments arranged at substantially right angles and a flat gusset segment extending between said end segments, and means projecting upwardly from said segments adapted to support and locate a border wire supporting spring element.

2. The structure according to claim 1 further including upright depending side portions on said end segments arranged at right angles with respect 4to each 5. The structure according to claim 3 wherein said rail means is releasably connected to said bracket means. Y

6. In a box spring assembly having a rectangular wooden frame with side and end rails joined. to formA corners and a border wire disposed above the frame, a corner bracket comprising a body member having a flat portion and a pair of integral upright side portions which depend from said flat portion, said side portions being arranged at a right angle with respect to each other for engaging the inside edges of said side and end rails at one of said corners so as to locate said flat portion in engagement with the top sides of said side and end rails at said one corner, means projecting from said flat portion and adapted to support and locate a border wire supporting spring element, and means extending from said flat portion into said side and end rails securing said body member to said frame.

7. The corner bracket that is defined in claim 6, wherein said flat portion is of increased width at a point adjacent to said corner of said frame.

8. The corner bracket that is defined in claim 6, wherein said flatportion has integral fastener means comprising a stamped-out segment having an end portion bent essentially perpendicular to said flat portion.

9. A corner bracket according to claim 6 further including slot means in said flat portion arranged in pairs and forming openings for staples to secure said body member to said frame. v

10. A corner bracket according to claim 6 wherein said means projecting from said flat portion comprises at least three angularly arranged tab members. 

1. In a box spring assembly having a rectangular frame with side and end rails joined to form corners and a border wire disposed above the frame, corner bracket means comprising a body member having flat end segments arranged at substantially right angles and a flat gusset segment extending between said end segments, and means projecting upwardly from said segments adapted to support and locate a border wire supporting spring element.
 2. The structure according to claim 1 further including upright depending side portions on said end segments arranged at right angles with respect to each other for engaging the inside edges of said side and end rails at one of said corners so as to locate said body member in engagement with the top sides of said side and end rails, and means securing said body member to said side and end rails.
 3. The structure according to claim 2 further including another corner bracket means like said first mentioned corner bracket means and rail means extending between and connecting said two bracket means.
 4. The structure according to claim 3 wherein said rail means is formed integral with said bracket means.
 5. The structure according to claim 3 wherein said rail means is releasably connected to said bracket means.
 6. In a box spring assembly having a rectangular wooden frame with side and end rails joined to form corners and a border wire disposed above the frame, a corner bracket comprising a body member having a flat portion and a pair of integral upright side portions which depend from said flat portion, said side portions being arranged at a right angle with respect to each other for engaging the inside edges of said side and end rails at one of said corners so as to locate said flat portion in engagement with the top sides of said side and end rails at said one corner, means projecting from said flat portion and adapted to support and locate a border wire supporting spring element, and means extending from said flat portion into said side and end rails securing said body member to said frame.
 7. The corner bracket that is defined in claim 6, wherein said flat portion is of increased width at a point adjacent to said corner of said frame.
 8. The corner bracket that is defined in claim 6, wherein said flat portion has integral fastener means comprising a stamped-out segment having an end portion bent essentially perpendicular to said flat portion.
 9. A corner bracket according to claim 6 further including slot means in said flat portion arranged in pairs and forming openings for staples to secure said body member to said frame.
 10. A corner bracket according to claim 6 wherein said means projecting from said flat portion comprises at least three angularly arranged tab members. 